Step rail for vehicle with applique and method of making same

ABSTRACT

An accessory component for a vehicle is disclosed which may incorporate an elongated frame element having an elongated channel formed there along. The elongated frame element is adapted to be fixedly secured to a portion of the vehicle. A resilient metallic applique having a contour generally in accordance with at least a portion of the elongated frame element may be incorporated. The applique may have a feature adjacent a first end for engaging with the elongated channel, and a second end of the applique may be shaped to engage with a different portion of the elongated frame element such that the applique is secured to the elongated frame element without adhesives or mechanical fasteners.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/384,986, filed Sep. 8, 2016. The entire disclosure of the aboveapplication is incorporated herein by reference.

FIELD

The present disclosure relates to step rails or step bars used to aidwith ingress and egress into and out from a vehicle interior, such as aSUV, van, truck, etc., and more particularly to a step rail having aconstruction involving the use of a Bright applique over a frame-likeelement, and a method of making same that eliminates the need and costof a chrome plating operation.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

Step rails are used on many different types of vehicles, for exampleSUVs, vans, mini-vans, pickup trucks. Often it is important to providenot only a sturdy step rail that can easily handle the weight of one ormore occupants at a time, but a step rail that has a pleasingappearance. Typically, one or more distinct portions of present day steprails are chrome plated to provide an aesthetically pleasing appearance.However, a chrome plating operation adds significant cost to the steprail, and in some cases may make up 50% or more of the total cost ofmanufacture of the step rail. Chrome plating also involves the use ofcaustic materials and processes that must be carefully managed. Thescrap rate of chrome plating is also relatively high, which adds to theoverall cost of a mass produced product.

It would therefore be a highly desirable to provide a step rail and aconstruction therefore which is able to provide a robust design, with anequally aesthetically appealing appearance, and without requiring theuse of chrome plating.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

In one aspect the present disclosure relates to an accessory componentfor a vehicle. The accessory component may incorporate an elongatedframe element having an elongated channel formed there along. Theelongated frame element is adapted to be fixedly secured to a portion ofthe vehicle. A resilient metallic applique may be included which has acontour generally in accordance with at least a portion of the elongatedframe element. The applique may have a feature adjacent a first end forengaging with the elongated channel. A second end of the applique may beshaped to engage with a different portion of the elongated frame elementsuch that the applique is secured to the elongated frame element withoutadhesives or mechanical fasteners.

In another aspect the present disclosure relates to an accessorycomponent for a vehicle that makes use of an elongated frame element.The elongated frame element may have an elongated semi-circular channelformed co-extensively there with, and at least at least one bracketsecured to the elongated frame element. The bracket is adapted to besecured to a frame portion of the vehicle and supports the elongatedframe element along a portion of the vehicle. A resilient metallicapplique is included which has a contour generally in accordance with atleast a portion of the elongated frame element. The applique has acurved portion adjacent a first end for engaging with the elongatedchannel. A second end of the applique is shaped to engage with adifferent portion of the elongated frame element. In this manner theapplique is able to be secured to the elongated frame element with asnap fit, and thus does not require adhesives or independent mechanicalfasteners.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

FIG. 1 is a perspective view a step rail in accordance with oneembodiment of the present disclosure;

FIG. 2 is an exploded perspective view of the major components of thestep rail of FIG. 1;

FIG. 3 is a side cross sectional view of the frame element shown in FIG.2 taken in accordance with section line 3-3 in FIG. 2;

FIG. 4 is a plan view of the applique shown in FIG. 2;

FIG. 5 is a side cross sectional view of the applique shown in FIG. 2 inaccordance with section line 5-5 in FIG. 2;

FIG. 6 is a rear view of the applique shown in FIG. 5;

FIG. 7 is an enlarged perspective view of one of the pads shown in FIG.2;

FIG. 8 is a side view of the pad shown in FIG. 7;

FIG. 9 is a cross sectional view through the pad of FIG. 8 taken inaccordance with section line 9-9 in FIG. 8;

FIG. 10 is a simplified cross sectional drawing of another embodiment ofthe present disclosure in which an applique is secured along both of itslongitudinal edges by a snap-fit to an elongated frame element; and

FIG. 11 is a simplified cross sectional drawing of still anotherembodiment which makes use of two independent.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is notintended to limit the present disclosure, application, or uses.

It should be understood that throughout the drawings, correspondingreference numerals indicate like or corresponding parts and features.

Referring to FIG. 1 an accessory component in the form a vehicle steprail 10 is shown in accordance with one embodiment of the presentdisclosure. In this example the accessory component forms a step railfor use with a motor vehicle, for example a pickup truck, SUV, minivan,full size van, etc. However, it will be appreciated that the teachingsof the present disclosure may be used to form other types of accessorycomponents (e.g., grab rails) where a polished looking, decorativefinish is desired. As such, the teachings described herein may even beused in connection with vehicle bumpers, vehicle mirrors, vehicle roofrack elements, etc., and therefore the teachings presented herein arenot limited solely to use with vehicle step rails.

In FIG. 1 the example vehicle step rail 10 may include an elongatedframe element 12 (obscured in FIG. 1), an applique 14, a front end cap16, a rear end cap 18, and a number of brackets 20 for securing the steprail 10 to a frame or body portion (not shown) of a vehicle 22. Aplurality of plastic, elastomeric or rubber pad members 24 may besecured to the applique to help provide a non-slip surface to furtherease ingress into, and egress from, the vehicle interior. The end caps16 and 18 may be telescopically fitted into the opposing ends of theframe element 12 and each may be held fixedly secured therein one of aplurality of threaded fasteners 34.

Referring to FIG. 2, the step rail 10 is shown in exploded perspectivefashion. In this example the frame element 12 forms an extruded aluminumcomponent. However, the frame element 12 could instead be formed from aroll forming process or any other forming process which is capable ofproducing an elongated, structurally strong component suitable forsupporting the weight of one or more individuals. Aluminum is apreferred material because of its relatively high strength and lightweight, but steel could also be used, and the frame element 12 is notlimited to use with any specific material. The frame element 12 may alsobe heat treated.

The step rail 10, as best shown in FIG. 3, may include an upper surface23 having a plurality of elongated channels 26 a and 26 b for engagingportions of the pad members 24, as will be described more fully in thefollowing paragraphs. A semi-circular channel 27 is formed along aforward edge 28 of the frame element 12 for engaging with a leading edgeportion of the applique 14. A rear surface 30 is used for attaching atrailing edge surface of the applique 14 to the frame element 12. Therear surface 30 may include a hole 32 at each end for enabling one ofthe fasteners 34 (visible in FIG. 1) to be used to hold each of the endcaps 16 and 18 within the opposing end portions of the frame element 12.While the frame element 12 is shown as a single piece component, it willbe appreciated that it could be formed from two or more distinctcomponents that are fixedly secured together.

Referring to FIGS. 4-6, the applique 14 is shown in greater detail. Theapplique 14 may be formed from aluminum or stainless steel and can havea highly polished outer surface which provides the appearance of beingchrome plated. Other manufacturing possibilities for generatingappearance differences include brushing, blasting and other impingementtechniques. The applique 14 also has pluralities of holes 38 and 40 foraccepting portions of the pads 24. The holes 38 and 40 are shown havingdifferent shapes, which helps to “key” attachment of the pads 24 in oneorientation only when the pads 24 are being installed on the frameelement 12. It is a principal benefit of the step rail 10 that thehighly polished outer surface 36 of the applique 14 is virtuallyindistinguishable from a chrome plated surface but is formed withoutincurring the cost and manufacturing complexity, and other drawbacks, ofa traditional chrome plating process.

FIG. 5 shows the applique 14 in cross section. The applique 14 has anoverall contour that matches that of the frame element 12. The applique14 includes a curved circular lip 42, a forward edge surface 44, a topsurface 46 a, an upwardly sloping upper portion 46 b and a rear surface48. An outer surface 49 of the applique 14 forms the highly polishedsurface portion.

The curved circular lip 42 may be inserted into the semi-circularchannel 27 and snaps therein during assembly, thus avoiding the use ofadhesives or threaded fasteners. The holes 38 and 40 are formed to bealigned with the channels 26 a and 26 b, respectively, when the applique14 is assembled to the frame element 12. An additional plurality ofholes 50 may be formed along the rear surface 48. When positioned on theframe element 12, the applique 14 lays over the upper surface 23 of theframe element 12 and the rear surface 48 of the applique 14 restsagainst the rear surface 30 of the frame element, and thus forms whatamounts to an outer skin for a major portion of the exterior surface ofthe frame element 12. The fasteners 34 shown in FIG. 1 may be insertedthrough the holes 50 in the rear surface 48 of the applique 14 intopreformed holes (not shown in the rear surface 34) to thus secure therear surface 48 of the applique 14 to the rear surface 30 of the frameelement 12.

Referring to FIGS. 7-9, one of the pads 24 is shown in greater detail.Each one of the pads 24 may form a single piece component which includesan upper body portion 52 and a pair of depending tabs 54 that each forma notch 56. The depending tabs 54 may be pushed through an aligned pair38/40 of the holes and then pressed into the channels 26 a and 26 b tosecure the pad 24 to the frame element 12. The edges of the holes 38 and40 engage the notches. 56 to prevent removal of the pad 24 once it isassembled to the frame element 12. Advantageously, the pads 24 help tosecure the applique 14 firmly to the upper surface 23 of the frameelement 12 without the use of adhesives or threaded fasteners. Theapplique 14 and the pads 24 can thus be secured quickly and without theuse of special tools or complex assembly procedures when assembling thestep rail 10.

The method of manufacturing the step rail 10 also forms a significantadvance in the art. The frame element 12 may initially be formed, forexample, using a conventional extrusion process or by using aconventional roll forming process. The applique 14 may initially beformed from a suitably sized piece of highly pre polished, non-corrosiveStainless Steel or brushed/smooth/blasted aluminum in sheet form, forexample 0.6 mm-1.5 mm thick. The Stainless Steel may be initiallypresented with a protective film thereon. The Stainless Steel may be ina coiled form and fed into a stamping press. A section of the StainlessSteel is initially stamped by the stamping press to form all of theholes 38 and 40 in one operation (also called an in-line pre-punchoperation). This avoids the need to drill, CNC, laser cut or otherwiseform the holes 38 and 40 one at a time, which would be time consumingand expensive from a labor standpoint. Using a stamping press to formthe holes 38/40 in one operation also ensures that the holes areprecisely formed every time an applique 14 is manufactured. The stamped,polished stainless or aluminum sheet may then be fed through rolls offormed into the precise shape and contour needed to fit onto the frameelement 12, with the curved circular lip 42 also being formed duringthis operation. The forming of the contour of the applique 14 may be byusing a conventional roll forming process in which the stamped, polishedstainless or brushed/smooth/blasted aluminum sheet is fed through rollsof a roll forming apparatus to form the stamped, polished stainless orbrushed/smooth/blasted aluminum sheet into the needed contour. The rollformed sheet may then be cut off at a precise length.

The pads 24 may be formed separately, for example in an injectionmolding process using a suitable high strength plastic. The pads 24 mayalso be molded or otherwise formed using an elastomeric material or fromrubber.

Referring to FIG. 10, a step rail 100 in accordance with anotherembodiment of the present disclosure is shown. The step rail 100 in thisexample includes an elongated frame element 102 and an applique 104which is secured to the frame with any external fastening elements(e.g., without threaded screws). The elongated frame element 102 may beformed in any manner, for example from an extruded section of aluminum,and it may be coated with any suitable coating as well (e.g., powdercoated). The frame element 102 includes a front wall 106, a top portion108, a rear portion 110 and a bottom portion 112. A first semi-circularchannel 114 is formed in the bottom portion 112 adjacent a lower edge ofthe front wall 106, and second channel 116 is formed in the rear portion110 adjacent the top portion 108. Two longitudinally extending channels117 a and 117 b are also formed for receiving the depending tab portions54 of the pads 24 as described above with the step rail 10. The applique104 includes a forward curved edge portion 118, a front portion 120, atop portion 122, and a rear curved edge portion 124. The applique 104also includes openings (not visible in FIG. 10), produced for example bystamping or any other suitable means, just like aligned pair of holes38/40 discussed above, which receive the depending tab portions 54.

When the applique 104 is to be assembled onto the elongated frameelement 102, the forward edge portion 118 is initially press fit into,that is snapped into, the forward semi-circular channel 114. This can beaccomplished by an assembly technician without the need for any specialtools. Once the forward semi-circular channel 114 is fully engaged withthe full length of the semi-circular channel 114, the top portion 122 isarticulated so that its top portion 122 lies generally over the topportion 108 of the elongated frame element 102. A surface area 126adjacent the rear curved edge portion 124 may then be pressed downwardin accordance with arrow 128, which causes the rear curved edge portion124 to be pushed over a rear edge lip 130 of the elongated frame element102 and to snap into the second channel 116. Thus, the entire applique104 can be secured to the elongated frame element 102 without the use ofany fastening elements, special tools or adhesives. Possibly, theassembly sequence could be reversed such that the rear curved edgeportion 124 is secured first, and the forward curved edge portion 118 issecured last. Optionally, one or more beads of adhesive may be depositedon an upper surface of the top portion 108, or along any other surfaceof the elongated frame element 102 where an undersurface of the applique104 will make contact with it, prior to installing the applique.

While the channels 114 and 116 have been illustrated with a partial orsubstantial semi-circular construction, it will be appreciated that thechannels may potentially be formed with other cross sectionalconfigurations as well. The important consideration is that the curvedportions 118 and 124 of the applique 104 are to engage with a wall oredge portion of a channel so that both curved portions 118 and 124 canbe snapped into their respective channels and be retained thereinwithout external fastening elements.

Referring to FIG. 11, a step rail 200 in accordance with anotherembodiment of the present disclosure is shown. In this example anelongated frame element 202 is provided which may be made from anysuitably strong material, for example high strength plastic or aluminum,and more preferably extruded aluminum. The elongated frame element 202may include a semi-circular shaped (in cross section) forward edgechannel 204 formed along a front surface 206 of the elongated frameelement, a first pair of elongated channels 208 a and 208 b and a secondpair of elongated channels 210 a and 210 b all formed along an uppersurface 212 of the elongated frame element. A semi-circular shapedrearward edge elongated channel 214 may be formed along a rear surface216 of the elongated frame element 202. A first applique 218 may besecured in the forward edge channel 204 and the elongated channel 210 a.A fully independent second applique 220 may be installed in channel 210b and the rearward elongated channel 214.

The first applique 218 may include a first leg portion 218 a thatengages a lip 210 a 1 of the elongated channel 210 a. A curved endportion 218 b may engage the forward edge channel 204. Installation ofthe first applique may be performed by first inserting the first legportion 218 in the elongated channel 210 a so that the first leg portionengages lip 210 a 1, and then rotating the first applique 218 clockwisein the illustration of FIG. 11 until the curved end portion 218 b entersthe forward edge channel 204. A snapping action may be required to fullyinsert the curved end portion 218 b as its free end 218 c clearly lip204 a of the forward edge channel 204.

The second applique 220 may be inserted in a similar fashion into thechannel 210 b and the rearward elongated channel 214 by first insertinga leg portion 220 a into the channel 210 b such that the leg portion 220a engages a lip 210 b 1 of the channel 210 b, and then rotating theentire second applique 220 counterclockwise until a curved end portion220 b enters the rearward edge elongated channel 214, and its free end220 c clears a lip 214 a of the rearward elongated channel 214 with asnapping-like engagement action.

Optionally, but preferably, the step rail 200 may also include an upperpad 222 having at least one, but preferably a plurality, of projectingconventional Christmas-tree style fastening posts 224 protruding from anundersurface 226 thereof. The fastening posts 224 enable the upper pad222 to be secured to the upper surface 212 of the elongated frameelement 202 by simply pressing the fastening posts 224 into the channels208 a and 208 b. The upper pad 222 may be made from rubber, plastic orany other suitable material that provides increased traction when anindividual steps on the step rail 200 to enter a vehicle.

The first and second appliques 218 and 220 may be made frombrushed/smooth/blasted stainless steel, or from polished aluminum or anyother material having a degree of resiliency and preferably a shiny,chrome-like appearance. Aluminum and stainless steel are metallicmaterials that are especially highly preferred because whenbrushed/smooth/blasted (i.e., generally speaking highly polished), theylook similar to chrome.

The method of attaching the first and second appliques 218 and 220 isespecially advantageous because the appliques 218 and 220 can beattached without any messy or toxic adhesives or external fasteners, andwithout special tools. Assembly of the appliques 218 and 220 to theelongated frame element 202 can be made quickly, typically within justminutes or less. If either applique 218 or 220 is damaged, the method ofassembly described herein would permit one or the other to be easilyreplaced.

The above manufacturing sequence may be varied and is not limited tohaving the above-described manufacturing operations performed in theexact order as described above. For example, the polishing of thealuminum sheet that forms the applique 14 may be performed after thestamping operation. Regardless of the exact sequence of manufacturingoperations, the applique 14 has a chrome-like appearance that isvirtually indistinguishable from a chrome plated surface. But sincechrome plating is avoided, the step rail 10 can be manufacturedsignificantly more economically than if conventional chrome plating wasused on the applique 14.

While various embodiments have been described, those skilled in the artwill recognize modifications or variations which might be made withoutdeparting from the present disclosure. The examples illustrate thevarious embodiments and are not intended to limit the presentdisclosure. Therefore, the description and claims should be interpretedliberally with only such limitation as is necessary in view of thepertinent prior art.

What is claimed is:
 1. An accessory component for a vehicle, comprising:an elongated frame element having an elongated channel formed therealong, the elongated frame element adapted to be fixedly secured to aportion of the vehicle; a resilient metallic applique having a contourgenerally in accordance with at least a portion of the elongated frameelement; the applique having a feature adjacent a first end for engagingwith the elongated channel, and a second end of the applique beingshaped to engage with a different portion of the elongated frame elementsuch that the applique is secured to the elongated frame element withoutadhesives or mechanical fasteners.
 2. The accessory component of claim1, wherein the accessory component comprises a step rail.
 3. Theaccessory component of claim 1, wherein the feature adjacent the firstend comprises a curved end portion.
 4. The accessory component of claim1, wherein the elongated channel is semi-circular shaped.
 5. Theaccessory component of claim 1, wherein: the elongated frame elementfurther comprises at least one channel formed in an upper surfacethereof; and a pad including at least one projecting post which is ableto be secured in the at least one channel in the upper surface.
 6. Theaccessory component of claim 1, wherein the elongated frame elementincludes an additional elongated channel spaced apart from the elongatedchannel, and an additional applique secured to the additional elongatedchannel.
 7. The accessory component of claim 1, wherein the elongatedchannel is formed at least one of on or adjacent to a forward edgesurface of the elongated frame element.
 8. The accessory component ofclaim 1, wherein the second end of the applique engages with a rearsurface of the elongated frame element.
 9. The accessory component ofclaim 1, wherein: the second end of the applique includes a leg portion;and the elongated frame element includes an additional channel along anupper surface thereof; and wherein the second end of the appliqueengages within the additional channel.
 10. The accessory component ofclaim 1, wherein the applique includes a plurality of holes formedtherein.
 11. An accessory component for a vehicle, comprising: anelongated frame element having an elongated semi-circular channel formedco-extensively there with; at least one bracket secured to the elongatedframe element and adapted to be secured to a frame portion of thevehicle, for supporting the elongated frame element along a portion ofthe vehicle; a resilient metallic applique having a contour generally inaccordance with at least a portion of the elongated frame element; theapplique having a curved portion adjacent a first end for engaging withthe elongated channel, and a second end of the applique being shaped toengage with a different portion of the elongated frame element such thatthe applique is secured with a snap fit to the elongated frame elementwithout adhesives or mechanical fasteners.
 12. The accessory componentof claim 11, wherein the accessory component comprises a step rail. 13.The accessory component of claim 11, wherein the applique comprises atleast one of polished stainless steel or polished aluminum.
 14. Theaccessory component of claim 11, wherein the applique comprises a leg atthe second end, and wherein the elongated frame element includes anadditional channel on an upper surface thereof, the leg engaging withinthe additional channel to help secure the applique to the elongatedframe element.
 15. The accessory component of claim 14, wherein theadditional channel comprises a lip that engages with the leg of theapplique to help hold the second end in the additional channel.
 16. Theaccessory component of claim 15, wherein the additional channel isformed co-extensive with a full length of the elongated frame element.17. The accessory component of claim 11, wherein the applique includes aplurality of holes formed therein.
 18. The accessory component of claim17, further comprising a pad that is secured to an upper surface of theelongated frame element over a portion of the applique.
 19. Theaccessory component of claim 18, wherein the elongated frame elementincludes an additional channel formed in the upper surface, and whereinthe pad includes a plurality of depending tabs, wherein the dependingtabs extending through the holes in the applique to engage in theadditional channel.
 20. The accessory component 11, wherein theelongated frame element includes an additional plurality of channelsformed co-extensively with the length of the elongated frame element;and further including an additional resilient, metallic applique securedin specific ones of the additional plurality of channels adjacent a reararea of the elongated frame element.